Reactive material compositions and projectiles including the same

ABSTRACT

A reactive material that includes at least one of a fuel, an oxidizer, and a class 1.1 explosive and is formulated for use in a reactive material projectile. The reactive material is formulated to provide at least one of an overpressure of greater than approximately 9 pounds per square inch at a radial measurement of 12 inches from a point of impact on a target, a hole greater than approximately 2 square inches at an optimum penetration level in a target, and pressure, damage, and a flame when the reactive material bullet impacts a target. The fuel may be a metal, a fusible metal alloy, an organic fuel, or mixtures thereof. The oxidizer may be an inorganic oxidizer, sulfur, a fluoropolymer, or mixtures thereof. A reactive material projectile having the reactive material disposed therein is also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/127,627, filed May 27, 2008, pending, which application is adivisional of U.S. patent application Ser. No. 10/801,948, filed Mar.15, 2004, abandoned. The disclosure of each of the previously-referencedU.S. patent applications is hereby incorporated herein in its entiretyby reference.

The present application is related to U.S. Provisional PatentApplication No. 60/368,284, filed Mar. 28, 2002, entitled LowTemperature, Extrudable, High Density Reactive Materials, now abandoned;U.S. Pat. No. 6,962,634, issued Nov. 8, 2005, entitled Low Temperature,Extrudable, High Density Reactive Materials; U.S. patent applicationSer. No. 12/507,605, filed Jul. 22, 2009, entitled Low Temperature,Extrudable, High Density Reactive Materials, pending; U.S. ProvisionalPatent Application No. 60/184,316, filed Feb. 23, 2000, entitled HighStrength Reactive Materials, now abandoned; U.S. Pat. No. 6,593,410,issued Jul. 15, 2003, entitled High Strength Reactive Materials; U.S.Pat. No. 7,307,117, issued Dec. 11, 2007, entitled High StrengthReactive Materials And Methods Of Making; U.S. patent application Ser.No. 10/801,946, filed Mar. 15, 2004, entitled Reactive CompositionsIncluding Metal, now abandoned; U.S. patent application Ser. No.11/620,205, filed Jan. 5, 2007, entitled Reactive Compositions IncludingMetal, now U.S. Pat. No. 8,075,715, issued Dec. 13, 2011; U.S.Provisional Application No. 60/553,430, filed Mar. 15, 2004, entitledReactive Material Enhanced Projectiles and Related Methods, nowabandoned; U.S. Pat. No. 7,603,951, issued Oct. 20, 2009, entitledReactive Material Enhanced Projectiles and Related Methods; U.S.Provisional Application No. 60/723,465, filed Oct. 4, 2005, entitledReactive Material Enhanced Projectiles And Related Methods, nowabandoned; U.S. patent application Ser. No. 11/538,763, filed Oct. 4,2006, entitled Reactive Material Enhanced Projectiles And RelatedMethods, now U.S. Pat. No. 8,122,833, issued Feb. 28, 2012; U.S. Pat.No. 7,614,348, issued Nov. 10, 2009, entitled Weapons And WeaponComponents Incorporating Reactive Materials And Related Methods; U.S.patent application Ser. No. 11/697,005, filed Apr. 5, 2007, entitledConsumable Reactive Material Fragments, Ordnance IncorporatingStructures For Producing The Same, And Methods Of Creating The Same,pending; and U.S. patent application Ser. No. 11/690,016, filed Mar. 22,2007, entitled Reactive Material Compositions, Shot Shells IncludingReactive Materials, and a Method of Producing Same, now U.S. Pat. No.7,977,420, issued Jul. 12, 2011.

FIELD OF THE INVENTION

The present invention relates to reactive materials and, morespecifically, to reactive materials suitable for use in a munition, suchas a reactive material projectile, as well as to munitions in the formof projectiles containing the reactive materials.

BACKGROUND OF THE INVENTION

Historically, it has been difficult to inflict catastrophic damage onthin-skinned targets using a long-range gun. The problem is even morepronounced with thin-skinned, fuel filled targets, such as fuel tanks,fuel containers, or fuel storage facilities. Conventional projectiles,such as MK211, M8, or M20 armor piercing incendiary (“API”) projectiles,are designed to penetrate armor plating and to provide an incendiaryflash. To provide the penetrating effects, the MK211, M8, and M20 APIprojectiles typically include a fill material that is an incendiarycomposition. For instance, in the MK211, the fill material includeszirconium sandwiched between Composition B. While these projectilespenetrate thin-skinned targets, the fill material does not initiate whenthe projectiles come into contact with the target surface. Rather, theprojectiles pass through the thin-skinned target and do not ignite fuelthat is contained within it. As such, the MK211, M8, and M20 APIprojectiles have limited effectiveness against thin-skinned targets.

A fill material for use in an armor-piercing projectile is disclosed inU.S. Pat. No. 4,237,787 to Wacula et al. The fill material is anincendiary composition that includes aluminum or magnesium, a nitrate orperoxide of potassium, strontium, or barium, and a binder, such as achlorinated binder. U.S. Pat. No. 4,112,846 to Gilbert et al. disclosesan incendiary material having a first metal, which interacts with asecond metal to form an intermetallic compound. The first metal iszirconium, titanium, thorium, hafnium, uranium, or mixtures thereof andis present from 70-98.5% by weight. The second metal is tin, lead, ormixtures thereof and is present from 1.5-30% by weight. Incendiarycompositions having various properties have also been disclosed. In U.S.Pat. No. 6,485,586 to Gill et al., a low burning rate, high temperatureincendiary composition is disclosed. The incendiary composition includestitanium, boron, polytetrafluoroethylene (“PTFE” or TEFLON®), andparaffin wax.

Incendiary materials have also been used as liners in projectiles, suchas in warheads. In U.S. Pat. No. 4,381,692 to Weintraub, a quasi alloyzirconium (“QAZ®”) material is disclosed for use in munitions. QAZ®includes a long chain epoxy and a powdered metal mixture of zirconium,aluminum, hafnium, magnesium, antimony, tin, and iron. Reactive orenergetic materials have also been disclosed for use as liners inprojectiles. A known reactive material includes a composition ofaluminum and PTFE, as disclosed in U.S. Pat. No. 6,547,993 to Joshi. InU.S. Pat. No. 5,886,293 to Nauflett et al., a process of producingenergetic materials for use in military pyrotechnics is disclosed. Theenergetic material includes a magnesium fluoropolymer, specificallymagnesium/TEFLON®NITON® (“MTV”).

In order to defeat thin-skinned targets and particularly those housingflammable materials, such as fuels, it would be desirable to produceprojectiles that initiate on contact with the thin-skinned target.Therefore, it would be desirable to formulate fill materials thatprovide a higher energy output than those currently used, such as in theMK211.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises a reactive material that includesreactive material components from at least two of the following threecomponent categories: at least one fuel, at least one oxidizer, and atleast one class 1.1 explosive. The reactive material is formulated foruse in a reactive material projectile, such as a bullet, and to provideat least one of an overpressure of greater than approximately 9 poundsper square inch at a radial measurement of 12 inches from a point ofimpact on a target, a hole greater than approximately 2 square inches atan optimum penetration level in a target, and pressure, damage, and aflame when the reactive material projectile impacts a target. Thereactive material may be formulated to initiate upon impact of theprojectile with a target.

The at least one fuel may be selected from the group consisting of ametal, a fusible metal alloy, an organic fuel, and mixtures thereof. Asuitable metal for the fuel may be selected from the group consisting ofhafnium, tantalum, nickel, zinc, tin, silicon, palladium, bismuth, iron,copper, phosphorous, aluminum, tungsten, zirconium, magnesium, boron,titanium, sulfur, magnalium, and mixtures thereof. A suitable organicfor the fuel may be selected from the group consisting ofphenolphthalein and hexa(ammine)cobalt(III)nitrate. A suitable, fusiblemetal alloy for the fuel may include at least one metal selected fromthe group consisting of bismuth, lead, tin, cadmium, indium, mercury,antimony, copper, gold, silver, and zinc. In one embodiment, the fusiblemetal alloy may have a composition of about 57% bismuth, about 26%indium, and about 17% tin.

The at least one oxidizer may be selected from the group consisting ofan inorganic oxidizer, sulfur, a fluoropolymer, and mixtures thereof.The at least one oxidizer may be an alkali or alkaline metal nitrate, analkali or alkaline metal perchlorate, or an alkaline metal peroxide. Forinstance, the at least one oxidizer may be ammonium perchlorate,potassium perchlorate, potassium nitrate, strontium nitrate, basiccopper nitrate, ammonium nitrate, cupric oxide, tungsten oxides, silicondioxide, manganese dioxide, molybdenum trioxide, bismuth oxides, ironoxide, molybdenum trioxide, or mixtures thereof. The at least oneoxidizer may also be selected from the group consisting ofpolytetrafluoroethylene, a thermoplastic terpolymer oftetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride, and acopolymer of vinylidenefluoride-hexafluoropropylene.

The at least one class 1.1 explosive may be selected from the groupconsisting of trinitrotoluene,cyclo-1,3,5-trimethylene-2,4,6-trinitramine, cyclotetramethylenetetranitramine, hexanitrohexaazaisowurtzitane,4,10-dinitro-2,6,8,12-tetraoxa-4,10-diazatetracyclo-[5.5.0.0^(5,9).0^(3,11)]-dodecane,1,3,3-trinitroazetine, ammonium dinitramide,2,4,6-trinitro-1,3,5-benzenetriamine, dinitrotoluene, and mixturesthereof. The reactive material may also include at least one binderselected from the group consisting of polyurethanes, epoxies,polyesters, nylons, cellulose acetate butyrate, ethyl cellulose,silicone, graphite, and(bis(2,2-dinitropropyl)acetal/bis(2,2-dinitropropyl) formal).

In one embodiment, the reactive material includes tungsten, potassiumperchlorate, and a copolymer of vinylidenefluoride-hexafluoropropylene.In another embodiment, the reactive material includes bismuth, indium,tin, potassium perchlorate, cellulose acetate butyrate, and(bis(2,2-dinitropropyl)acetal/bis(2,2-dinitropropyl)formal). In anotherembodiment, the reactive material includes aluminum, zirconium, and acopolymer of vinylidenefluoride-hexafluoropropylene. In anotherembodiment, the reactive material includes magnesium, cupric oxide, anda copolymer of vinylidenefluoride-hexafluoropropylene. In anotherembodiment, the reactive material includes hafnium and a thermoplasticterpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidenefluoride. In another embodiment, the reactive material includesaluminum, boron, and a copolymer ofvinylidenefluoride-hexafluoropropylene. In another embodiment, thereactive material includes zirconium and polytetrafluoroethylene. Inanother embodiment, the reactive material includes bismuth, indium, tin,and potassium perchlorate.

In another embodiment, the reactive material includescyclotetramethylene tetranitramine, cellulose acetate butyrate, and(bis(2,2-dinitropropyl)acetal/bis(2,2-dinitropropyl) formal). In anotherembodiment, the reactive material includes aluminum, potassiumperchlorate, silicon, and a thermoplastic terpolymer oftetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride. Inanother embodiment, the reactive material includes bismuth, indium, tin,aluminum, silicon, sulfur, potassium perchlorate, bisazidomethyloxetane,glycidylazide plasticizer, and(bis(2,2-dinitropropyl)acetal/bis(2,2-dinitropropyl)formal). In anotherembodiment, the reactive material includes cyclotetramethylenetetranitramine, cellulose acetate butyrate,(bis(2,2-dinitropropyl)acetal/bis(2,2-dinitropropyl)formal), aluminum,potassium perchlorate, silicon, and a thermoplastic terpolymer oftetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride. Inanother embodiment, the reactive material includes zirconium and athermoplastic terpolymer of tetrafluoroethylene, hexafluoropropylene,and vinylidene fluoride.

The present invention also comprises a reactive material projectile,which may be referred to as a “bullet” for convenience and notlimitation as to configuration or caliber, that includes a chamber orcavity therein containing the reactive material. In an exemplaryembodiment, the projectile may be configured as a case containing atleast one reactive material, and a tip. The at least one reactivematerial may be one, or a combination of two or more of, the reactivematerials referenced above. The technique employed to convey theprojectile to a target may be entirely conventional, and the techniqueselected in any given instance is nonlimiting as to the scope of thepresent invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming that which is regarded as the present invention,the advantages of this invention may be more readily ascertained fromthe following description of the invention when read in conjunction withthe accompanying drawings in which:

FIG. 1 is a schematic of an exemplary reactive material bullet thatincludes a reactive material of the present invention;

FIG. 2 is a schematic illustration of a hundred-yard test range used totest reactive material bullets including reactive materials of thepresent invention;

FIGS. 3-14 are pressure-versus-time profiles for reactive materialbullets including reactive materials of the present invention;

FIGS. 15-33 are still photos taken from high-speed video for reactivematerial bullets including reactive materials of the present invention;

FIGS. 34-53 are infrared intensity-versus-time profiles for reactivematerial bullets including reactive materials of the present invention;and

FIGS. 54-56 are bar graphs that summarize reactive material formulationsthat provide good target damage, plume size, and pressure output,respectively.

DETAILED DESCRIPTION OF THE INVENTION

A reactive material that is suitable for use in a projectile isdisclosed. Upon initiation, the reactive material produces an energyoutput or release that is greater than the energy output of the fillmaterial used in the MK211 projectile. The reactive material may alsohave a higher density than that of a conventional fill material. Thereactive material may be a high energy pyrotechnic composition. As usedherein, the term “pyrotechnic composition” refers to a composition thatproduces light, heat, motion, noise, pressure, or smoke when initiated.The reactive material may be used as a fill material in the projectile,such as in a bullet. The reactive material may provide enhancedperformance to a projectile in comparison to that provided byconventional fill materials, in at least one of pressure release,earlier initiation, later initiation, fireball intensity, and targetdamage. By modifying the components and their relative amounts in thereactive material, the energy release of the reactive material may betailored to specific target requirements so that damage to a targethaving known or projected characteristics may be maximized. Furthermore,by varying mechanical properties, such as material and configuration ofa case and tip of the reactive material projectile, and matching thosemechanical properties with a selected reactive material of the presentinvention, tailorable initiation and energy release may be achieved.

The reactive material may be an intermetallic-type composition, athermite-type composition, or a class 1.1 explosive-type compositionthat includes reactive material components from at least two of thefollowing three component categories: at least one fuel, at least oneoxidizer, and at least one class 1.1 explosive. The reactive materialmay also include more than one fuel, more than one oxidizer, or morethan one class 1.1 explosive. The relative amounts of the fuel, theoxidizer, or the class 1.1 explosive present in the reactive materialmay be varied depending on the desired properties of the reactivematerial. The fuel may be present in the reactive material fromapproximately 15% by weight to approximately 90% by weight, depending onthe type of fuel that is used. Percentages of each of the components inthe reactive material are expressed as percentages by weight (“wt %”) ofthe total weight of the reactive material. The fuel may be a metal, anorganic fuel, a fusible metal alloy, or mixtures thereof.

The metal used as a fuel may be hafnium (Hf), aluminum (Al), tungsten(W), zirconium (Zr), magnesium (Mg), boron (B), titanium (Ti), sulfur(S), tantalum (Ta), nickel (Ni), zinc (Zn), tin (Sn), silicon (Si),palladium (Pd), bismuth (Bi), iron (Fe), copper (Cu), phosphorous (P),magnalium (an alloy of Al and Mg), or mixtures thereof. For instance,aluminum may be used in combination with other elements, such ashafnium, boron, or zirconium, to form intermetallic-type reactivematerials. The metal may have a particle size ranging from approximately20 nm to approximately 300 μm. For the sake of example only, the metalmay be present in the reactive material in an amount ranging fromapproximately 10% to approximately 90%.

The fuel may also be an organic fuel, such as phenolphthalein orhexa(ammine)cobalt(III)nitrate (“HACN”). The organic fuel may be presentin the reactive material from approximately 15% to approximately 80%.

Further, the fuel may be a fusible metal alloy. Fusible metal alloys areknown in the art and are commercially available from sources including,but not limited to, Indium Corp. of America (Utica, N.Y.), AlchemyCastings (Ontario, Canada, and Johnson Mathey PLC (Wayne, Pa.). Thefusible metal alloy may be a eutectic or a noneutectic alloy and mayinclude transition metals and post-transition metals, such as metalsfrom Group III, Group IV, and/or Group V of the Periodic Table of theElements. The metals used in the fusible metal alloy may include, butare not limited to, Bi, lead (Pb), Sn, cadmium (Cd), indium (In),mercury (Hg), antimony (Sb), Cu, gold (Au), silver (Ag), Zn, andmixtures thereof. For the sake of example only, the fusible metal alloymay be Wood's Metal, which has 50% Bi, 25% Pb, 12.5% Sn, and 12.5% Cdand is available from Sigma-Aldrich Co. (St. Louis, Mo.). Wood's Metalhas a melting point of approximately 70° C. and a density of 9.58 g/cm³.The fusible metal alloy may also be INDALLOY® 174, which has 57% Bi, 26%In, and 17% Sn. INDALLOY® 174 has a melting point of 174° F.(approximately 79° C.), a density of 8.54 g/cm³, and is commerciallyavailable from Indium Corp. of America. Other INDALLOY® materials areavailable from Indium Corp. of America and may be used in the reactivematerial. INDALLOY® materials are available in a range of melting points(from approximately 60° C. to approximately 300° C.) and include avariety of different metals. As such, the fusible metal alloy for use inthe reactive material may be selected depending on the desired meltingpoint. The fusible metal alloy may be present in the reactive materialfrom approximately 14% to approximately 86%.

The oxidizer may be present in the reactive material from approximately10% to approximately 81%, depending on the oxidizer used. The oxidizerused in the reactive material may be an inorganic oxidizer, such as anammonium nitrate, an alkali metal nitrate, an alkaline earth nitrate, anammonium perchlorate, an alkali metal perchlorate, an alkaline earthperchlorate, an ammonium peroxide, an alkali metal peroxide, or analkaline earth peroxide. The inorganic oxidizer may include, but is notlimited to, ammonium perchlorate (“AP”), potassium perchlorate (“KP”),potassium nitrate (KNO₃), or strontium nitrate (SrNO₃). The inorganicoxidizer may have a particle size ranging from approximately 1 μm toapproximately 250 μm. The perchlorate or nitrate inorganic oxidizer maybe present from approximately 10% to approximately 90%. The inorganicoxidizer may also be a transition metal-based oxidizer, such as acopper-based, an iron-based, or a molybdenum-based oxidizer, thatincludes, but is not limited to, basic copper nitrate ([Cu₂(OH)₃NO₃])(“BCN”), cupric oxide (CuO), iron oxide (Fe₂O₃), or molybdenum trioxide(MoO₃). The transition metal-based oxidizer may be present fromapproximately 18% to approximately 78%. The transition metal-basedoxidizer may have a particle size ranging from approximately 20 nm toapproximately 200 μm. The oxidizer may also be a nonoxygen containingcompound, such as sulfur or a fluoropolymer, such as PTFE, athermoplastic terpolymer of tetrafluoroethylene, hexafluoropropylene,and vinylidene fluoride (“THV”), or a fluoroelastomer. Examples offluoropolymers include, but are not limited to TEFLON®, which isavailable from DuPont (Wilmington, Del.), THV220 or THV500, which areavailable from Dyneon LLC (Oakdale, Minn.), and VITON®, which is acopolymer of vinylidenefluoride-hexafluoropropylene and is availablefrom DuPont Dow Elastomers LLC (Wilmington, Del.). The fluoropolymer mayalso function as a binder in the reactive material. The fluoropolymermay be present from approximately 5% to approximately 74%.

The class 1.1 explosive may be present in the reactive material fromapproximately 14 wt % to approximately 94 wt %. The class 1.1 explosivemay be an energetic solid fuel, such as trinitrotoluene (“TNT”);cyclo-1,3,5-trimethylene-2,4,6-trinitramine (“RDX,” also known ashexogen or cyclonite); cyclotetramethylene tetranitramine (“HMX,” alsoknown as octogen); hexanitrohexaazaisowurtzitane (“CL-20,” also known asHNIW);4,10-dinitro-2,6,8,12-tetraoxa-4,10-diazatetracyclo-[5.5.0.0^(5,9).0^(3,11)]-dodecane(“TEX”); 1,3,3-trinitroazetine (“TNAZ”); ammonium dinitramide (“ADN”);2,4,6-trinitro-1,3,5-benzenetriamine (“TATB”); dinitrotoluene (“DNT”);dinitroanisole (“DNAN”), and mixtures thereof. The energetic solid fuelmay have a particle size ranging from approximately 1 μm toapproximately 150 μm.

The reactive material may optionally include additional ingredients,such as at least one of a binder, a processing aid, and a plasticizer,depending on the fuel(s), oxidizer(s), and class 1.1 explosive(s)employed and the desired properties of the reactive material. Examplesof energetic binders and nonenergetic binders that may be used include,but are not limited to, polyurethanes, epoxies, glycidyl azide polymer(“GAP”), silicone, polyesters, nylons, cellulose acetate butyrate(“CAB”), cellulose butyrate nitrate (“CBN”), ethyl cellulose,bisazidomethyloxetane (“BAMO”), and fluoropolymers. Examples ofprocessing aids include, but are not limited to, silicone, graphite, andPTFE. The plasticizer may include, but is not limited to,(bis(2,2-dinitropropyl)-acetal/bis(2,2-dinitropropyl)formal)(“BDNPA/F”), glycidylazide plasticizer (“GAP”), and polyglycidyl nitrate(“PGN”).

The reactive material may be formed by conventional techniques, such asby pressing, casting, or extruding. For instance, if the reactivematerial is an intermetallic-type, thermite-type composition, or class1.1 explosive-type composition, the fuel, the oxidizer, the class 1.1explosive, or any optional ingredients may be mixed, as known in theart. The reactive material may then be formed into a desired shape ormay be loaded into the bullet or other projectile by conventionaltechniques, such as by casting, pressing, or extruding. In oneembodiment, the reactive material includes THV, such as THV220 orTHV500. If the reactive material includes THV, the reactive material maybe easily formed, such as by hot pressing or extruding.

If the reactive material includes a fusible metal alloy, the reactivematerial may be formed by adding the oxidizer(s), the fuel(s), the class1.1 explosive(s), or any optional ingredients, such as binders,plasticizers, or processing aids, to the fusible metal alloy to form asubstantially homogenous mixture. The fusible metal alloy may be used ina liquid state, which is produced by heating the fusible metal alloy toa temperature above its melting point. As such, the fusible metal alloymay define a continuous phase and the remaining components may bedispersed therein. In other words, the fusible metal alloy may provide ametallic melt phase to which the remaining components are added. Aftermixing, the reactive material may be formed by conventional techniques.For instance, the reactive material may be placed into a mold orcontainer having a desired shape. The reactive material including thefusible metal alloy may be melt-poured or may be granulated and thenpressed. The reactive material may then be solidified to form thedesired shape. The reactive material may also be formed by placing it ina mold and pressing into the desired shape.

When used in a reactive material projectile, the reactive material maygenerate at least one of a higher overpressure, earlier initiation,later initiation, greater damage at the target, and larger plume sizeand intensity than conventional fill materials, such as the fillmaterial used in a MK211 projectile. If pressure release is a primarydesired output of the reactive material projectile, the reactivematerial may be formulated to generate an overpressure of greater thanapproximately 9 pounds per square inch (“psi”) at a radial measurementof 12 inches from the point of impact on a target. Alternatively, iftarget damage is the primary desired output, the reactive materialprojectile may be formulated to produce a hole in a target greater thanapproximately 2 square inches at an optimum penetration level. Ifinitiation is the primary desired output, the reactive material may beformulated to provide pressure, damage, and a flame when the reactivematerial projectile impacts a target. By utilizing the reactive materialof the present invention, the reactive material projectile may defeat athin-skinned target. As used herein, the term “thin-skinned target”refers to a target having a thickness of less than about 0.25 inch. Thethin-skinned target may be a vehicle, such as a car, aircraft, orwatercraft. The thin-skinned target may also be an incoming missile orother projectile, a building, or a fuel storage container. For the sakeof example only, a reactive material bullet according to the presentinvention may be used to defeat a fuel tank or fuel container, whichtypically has a wall thickness of at least 0.064 inch. The reactivematerial of the present invention may also be used, by way of exampleonly, in a reactive material bullet that is capable of penetrating athicker-skinned target, such as a target having a wall thickness of upto approximately ⅞-inch.

While the reactive material may be used as the fill material in abullet, the reactive material may also be used in other munitions, suchas in mortars or as a bombfill. For the sake of example only, thereactive material may be used in a projectile, such as the ballisticprojectiles disclosed in U.S. Pat. No. 4,419,936 to Coates et al. Thereactive material may also be used in a 0.50 caliber bullet. Forinstance, the reactive material may be used in a bullet that is designedto penetrate a thin-skinned target having a wall thickness of at least0.064 inch. However, the reactive material may also be used in a bulletthat is designed for greater penetration, such as into a thicker-skinnedtarget having a wall thickness of up to approximately ⅞-inch. Thereactive material may also be used as the fill material in other 0.50caliber casings, such as in the MK211, M8, or M20 casings. The reactivematerial may also be used in medium caliber projectiles, such as, forexample, in 35 mm, 30 mm, 25 mm and 20 mm cannon rounds, and in smallcaliber projectiles, such as, for example, in 0.223 caliber, 0.308caliber, 0.45 caliber, and 9 mm bullets. The reactive material may alsobe used in larger caliber guns that provide direct or indirect fire.

An exemplary reactive material bullet 2 may have a case 4, a reactivematerial 8 disposed in a cavity 4 c or chamber in the case, the mouth ofthe cavity 4 c being closed by tip 6 at the forward end of the bullet 2,as schematically shown in FIG. 1. The cavity 4 c in the reactivematerial bullet 2 may be larger than the chamber in a conventionalincendiary bullet. The reactive material 8 may be loaded into a core ofthe reactive material bullet 2 by conventional techniques. For instance,the reactive material 8 may be pressed into the bullet core from thefront of the case 4 at the mouth of cavity 4 c. Alternatively, thereactive material 8 may be cast into a desired shape and placed in thecase 4, or poured (cast) in a liquid state directly into the cavity 4 c.Once the reactive material 8 is loaded into the case 4, the tip 6 may beinserted into the case 4 to complete fabrication of the reactivematerial bullet 2. Since the cavity 4 c is larger than in a conventionalincendiary bullet, the reactive material bullet 2 may utilize a largervolume of the reactive material 8 than conventional projectiles. Forinstance, the reactive material bullet 2 may utilize up to four timesthe volume of the reactive material 8 than is employed in the MK211projectile.

When the reactive material bullet 2 is fired at a target, the mass andvelocity of the reactive material bullet 2 may provide sufficient energyfor the reactive material bullet 2 to penetrate the target. The materialand configuration of the tip 6 may be selected in relation to the wallthickness of the intended target. The initial impact of the reactivematerial bullet 2 with the target may initiate or ignite the reactivematerial 8. As the tip 6 of the reactive material bullet 2 begins topenetrate the target, the tip 6 may be pushed back into the reactivematerial 8 and the shock of impact, as conveyed to the reactive material8 by the tip 6, used to initiate the reactive material 8. If the targetis, for example, a fuel tank or other container holding a volatileliquid, the impact may initiate reaction of the reactive material 8 asthe tip 6 punctures the fuel tank, enabling fuel or other volatileliquid to escape and aerosolize in the atmosphere. As the reactivematerial bullet 2 continues to penetrate the target, the case 4 may beruptured by the ongoing reaction of the reactive material 8, expellinghot, burning material into the vaporized fuel or other volatile liquidand igniting the fuel. Since the reactive material 8 may be initiated bythe shock of impact of reactive material bullet 2 with the target,inclusion in reactive material bullet 2 of a separate initiationmechanism (such as a fuse or primer) for the reactive material 8 may notbe necessary. While the reactive material 8 may be initiated onthin-skinned targets, such as targets having walls made of 1/16-inchsteel, projectiles using reactive material 8 may also be used topenetrate thicker-skinned targets, such as those up to ⅞-inch steel wallthickness.

Although not required, the reactive material bullet 2 may optionallyinclude a primer and a propellant to initiate the reactive material 8.Upon firing the reactive material bullet 2, the primer initiates thepropellant, which in turn ignites the reactive material 8.

In one embodiment, the reactive material includes a mixture of 90% byweight (“wt %”) Hf powder and 10 wt % THV220, which is designated asFormulation 1943-32-12. Formulation 1943-32-12 provides a largefireball/plume size when ignited and also provides extensive targetdamage. In another embodiment, the reactive material provides ahigh-pressure release and includes a mixture of PAX-2A (86.6% HMX, 8%BDNPA/F and 5.4% cellulose acetate butyrate) and Formulation 1943-37A(13.7% THV220 fluoropolymer, 27.45% aluminum powder, 44.56% potassiumperchlorate, and 14.29% silicon). The reactive material included amixture of 50% by volume PAX-2A and 50% by volume Formulation 1943-37A.A sandwich of this reactive material was formed by first pressing thePAX-2A and then pressing the Formulation 1943-37A on top of the pressedPAX-2A to give a reactive material having 30% by weight PAX-2A and 70%by weight Formulation 1943-37A.

The following examples serve to explain embodiments of the presentinvention in more detail. These examples are not to be construed asbeing exhaustive or exclusive as to the scope of this invention.

EXAMPLES Example 1 Formulations of the Reactive Materials

Formulations of the reactive materials of the present invention areshown in Tables 1-3. Formulations of intermetallic and thermitecompositions are shown in Table 1.

TABLE 1 Formulations of Intermetallic and Thermite Reactive Materials.Ingredient 1 Ingredient 2 Ingredient 3 Ingredient 4 Mix Wt. Wt. Wt. Wt.Number Name % Name % Name % Name % 1791-97-10 Zr 34.62 CuO 60.82 VITON ®A 5 — — 1791-97-11 Al 17.52 CuO 77.48 VITON ® A 5 — — STR: 22235 Al-5μ44.2 PTFE 55.8 — — — — STR: 22037 Al-5μ 28.3 PTFE 71.7 — — — — STR:22080 Al-H95 28.3 PTFE 71.7 — — — — 1836-90C Phenolphthalein 20.5KNO₃-15μ 46.5 KClO₄-9μ 30 PVA 3 1836-90D Phenolphthalein 15.6 KNO3-15μ51.4 KClO₄-9μ 30 PVA 3 STR: 22610 SrNO₃ 66.54 Mg 31.71 Nylon 1.75 — —1791-100-1 W-690 nm 82.2 KP-5μ 10.3 VITON ® A 7.5 — — 1791-100-2 W-690nm 72.2 KP-5μ 20.3 VITON ® A 7.5 — — 1943-77A Nano-Al 26 PTFE 74 — — — —2002-1-1 Zr 47.7 PTFE 52.3 — — — — 1943-77B Nano-Al 27 MoO₃ 23 PTFE 50 —— 1943-77D Zn 56.75 PTFE 43.25 — — — — 1661-60A Magnalium 24.5 BCN-12.5μ68.5 Ethyl Cellulose 7 — — 1661-60D Al 27.5 BCN-12.5μ 68.1 EthylCellulose 4.5 — — 1775-50A HACN 79 BCN-12.5μ 18 Fe₂O₃ 3 — — 1791-97-1Al-H5 52.74 Boron 42.26 VITON ® A 5 — — 1791-97-2 Al-H5 50.33 Titanium44.67 VITON ® A 5 — — 1791-97-3 Al-H5 35.31 Zirconium 59.69 VITON ® A 5— — 1791-97-4 Titanium 65.45 Boron 29.55 VITON ®A 5 — — 1791-97-5Zirconium 76.8 Boron 18.2 VITON ® A 5 — — 1791-97-7 Hafnium 84.74 Boron10.26 VITON ® A 5 — — 1791-97-8 Mg (−325 mesh) 22.23 CuO 72.77 VITON ® A5 — — 1791-97-9 Titanium 21.98 CuO 72.02 VITON ® A 5 — — 1791-97-12 Hf50.23 CuO 44.77 VITON ® A 5 — — 1943-26D Al-H5 50 KP-100μ 10 THV220 40 —— 1943-26F Zr 65 THV220 35 — — — — 1943-26E Hf 90 THV220 10 — — — —1943-37A Al 27.45 THV220 13.7 KP 44.56 Si 14.29 1943-32-03 Al-H5 35.31Zr 59.69 VITON ® A 5 1943-32-07 Mg (−325 mesh) 22.23 CuO 72.77 VITON ® A5 1943-32-01 Al-H5 52.74 Boron 42.26 VITON ® A 5 Al-H95 = sphericalaluminum having a particle size of approximately 95 microns Al-H5 =spherical aluminum having a particle size of approximately 5 micronsNano-Al = aluminum having a particle size of approximately 5 microns

Formulations of class 1.1 explosive compositions are shown in Table 2.

TABLE 2 Formulations of Class 1.1 Reactive Materials. Ingredient 1Ingredient 2 Ingredient 3 Ingredient 4 Ingredient 5 Ingredient 6Ingredient 7 Mix Wt. Wt. Wt. Wt. Wt. Wt. Wt. Number Name % Name % Name %Name % Name % Name % Name % PAX-2A HMX 85 CAB 6 BDNPA/F 9 — — — — — — —— PAX-22a - CL-20 92 CAB 3.2 BDNPA/F 4.8 — — — — — — — — 1855-70 Form10 - CL-20 92 CBN 3.2 BDNPA/F 4.8 — — — — — — — — 1855-66 PAX-11c -CL-20 94 CAB 0.58 BDNPA/F 5.18 Graphite 0.24 — — — — — — 1943-02PAX-11c - CL-20 94 BAMO-PGN 3 BDNPA/F 3 — — — — — — — — 1943-15 Form 9 -CL-20 94 CBN 2.4 BDNPA/F 3.6 — — — — — — — — 1855-53 1943-03H IND 17414.25 KP-100μ 80.9 CAB 0.6 BDNPA/F 4 Graphite 0.3 — — — — 1943-03I IND174 14.25 AP-100μ 80.9 CAB 0.6 BDNPA/F 4 Graphite 0.3 — — — — 1943-03FIND 174 18.45 RDX-100μ 81.95 CAB 0.55 BDNPA/F 3.75 Graphite 0.25 — — — —1943-04G IND 174 20 CL-20-100μ 69.75 CAB 1 BDNPA/F 9 Graphite 0.25 — — —— 1943-03E IND 174 21.43 AP-100μ 71.43 CBN 0.89 BDNPA/F 5.89 Graphite0.36 — — — — 1943-03J IND 174 24.25 KP-100μ 33.75 RDX-100μ 33.75 CAB 1BDNPA/F 6.75 Graphite 0.5 — — 1943-04F IND 174 25 KP-100μ 27.75 RDX-100μ27.75 Mg −325 10 CAB 1.5 BDNPA/F 7.75 Graphite 0.25 1943-04F- IND 174 25KP-100μ 27.75 RDX-100μ 27.75 Mg −325 10 CAB 1.5 BDNPA/F 7.75 Graphite0.25 B 1943-04B IND 174 66.67 KP-100μ 14.28 RDX-100μ 14.28 CBN 0.57BDNPA/F 3.92 Graphite 0.28 — — 1943-04A IND 174 67.6 KP-100μ 14.45RDX-100μ 14.45 CAB 0.43 BDNPA/F 2.89 Graphite 0.22 — — 1943-32- IND 17454.3 KP-100μ 18.1 TNT 18.1 CAB 1.5 BDNPA/F 7.75 Graphite 0.25 — — 17

Formulations of INDALLOY®-containing compositions are shown in Table 3.

TABLE 3 Formulations of INDALLOY ®-containing Reactive Materials.Ingredient 1 Ingredient 2 Ingredient 3 Ingredient 4 Ingredient 5Ingredient 6 Ingredient 7 Mix Wt. Wt. Wt. Wt. Wt. Wt. Wt. Number Name %Name % Name % Name % Name % Name % Name % 1943-32- IND 174 14.25 KP-100μ80.9 CAB 0.6 BDNPA/F 4 Graphite 0.3 13 1943-03H IND 174 14.25 KP-100μ80.9 CAB 0.6 BDNPA/F 4 Graphite 0.3 — — — — 1943-03I IND 174 14.25AP-100μ 80.9 CAB 0.6 BDNPA/F 4 Graphite 0.3 — — — — 1943-03D IND 17416.67 KP-100μ 77.78 CBN 0.68 BDNPA/F 4.58 Graphite 0.28 — — — — 1943-03BIND 174 18.18 RDX-100μ 75.76 CBN 0.76 BDNPA/F 5 Graphite 0.3 — — — —1943-03F IND 174 18.45 RDX-100μ 81.95 CAB 0.55 BDNPA/F 3.75 Graphite0.25 — — — — 1943-04G IND 174 20 CL-20-100μ 69.75 CAB 1 BDNPA/F 9Graphite 0.25 — — — — 1943-04H IND 174 20 CL-20-100μ 55 Mg −325 14.75CAB 1 BDNPA/F 9 Graphite 0.25 — — 1943-03G IND 174 20.2 CL-20-100μ 72.9CAB 0.85 BDNPA/F 5.65 Graphite 0.4 — — — — 1943-03E IND 174 21.43AP-100μ 71.43 CBN 0.89 BDNPA/F 5.89 Graphite 0.36 — — — — 1943-03J IND174 24.25 KP-100μ 33.75 RDX-100μ 33.75 CAB 1 BDNPA/F 6.75 Graphite 0.5 —— 1943-32- IND 174 24.25 KP-100μ 33.75 RDX-100μ 33.75 CAB 1 BDNPA/F 6.75Graphite 0.5 14 1943-04F IND 174 25 KP-100μ 27.75 RDX-100μ 27.75 Mg −32510 CAB 1.5 BDNPA/F 7.75 Graphite 0.25 1943-04F- IND 174 25 KP-100μ 27.75RDX-100μ 27.75 Mg −325 10 CAB 1.5 BDNPA/F 7.75 Graphite 0.25 B 1943-03CIND 174 26.09 CL-20-100μ 65.22 CBN 1.09 BDNPA/F 7.17 Graphite 0.43 — — —— 1943-03K IND 174 29.6 KP-100μ 30.2 RDX-100μ 30.2 CBN 1.2 BDNPA/F 8.3Graphite 0.6 — — 1943-34A IND 174 50 KP-100μ 30 CAB 2 BDNPA/F 18 — — — —— — 1943-34B IND 174 54 KP-100μ 36 BAMO-PGN 1 BDNPA/F 9 — — — — — —1943-34C IND 174 54 KP-100μ 36 BAMO- 1 BDNPA/F 9 — — — — — — GAP1943-04C IND 174 56.85 KP-100μ 37.9 CAB 1 BDNPA/F 4 Graphite 0.25 — — —— 1943-04C- IND 174 56.85 KP-100μ 37.9 CAB 1 BDNPA/F 4 Graphite 0.25 — —— — B 1943-34D IND 174 60 KP-5μ 40 — — — — — — — — — — 1943-04B IND 17466.67 KP-100μ 14.28 RDX-100μ 14.28 CBN 0.57 BDNPA/F 3.92 Graphite 0.28 —— 1943-04A IND 174 67.6 KP-100μ 14.45 RDX-100μ 14.45 CAB 0.43 BDNPA/F2.89 Graphite 0.22 — — 1943-04D IND 174 75.8 KP-100μ 18.95 CAB 1 BDNPA/F4 Graphite 0.25 — — — — 1943-04D- IND 174 75.8 KP-100μ 18.95 CAB 1BDNPA/F 4 Graphite 0.25 — — — — B 1943-34E IND 174 80 KP-5μ 20 — — — — —— — — — — 1943-04E IND 174 85.28 KP-100μ 9.48 CAB 1 BDNPA/F 4 Graphite0.25 — — — — 1943-04E- IND 174 85.28 KP-100μ 9.48 CAB 1 BDNPA/F 4Graphite 0.25 — — — — B 1943-32- IND 174 54.3 KP-100μ 18.1 TNT 18.1 CAB1.5 BDNPA/F 7.75 Graphite 0.25 — — 17 1943-37B IND 174 15 KP-100μ 46Al-H5 15 Si 8 S 6 BAMO- 1 BDNPA/F 9 GAP IND 174 = INDALLOY ® 174

Each of the formulations was prepared by adding the ingredients to amixer and mixing the ingredients to obtain a homogenous mixture.

Example 2 Safety Testing of the Reactive Material Formulations

Safety testing was performed on the reactive material formulationsdescribed in Example 1. Friction properties of the formulations weremeasured using a friction test developed by Allegheny BallisticsLaboratory (“ABL”). Onset of ignition exotherms and sensitivity toelevated temperatures of the formulations were measured using aSimulated Bulk Autoignition Test (“SBAT”). Electrostatic discharge(“ESD”) of the formulations was measured using an ESD test developed byThiokol Corporation (“TC”). Impact properties of the formulations weremeasured using an impact test developed by TC and an impact testdeveloped by ABL. Deflagration to detonation (“DDT”) transitions of theformulations was also measured. These tests are known in the art and,therefore, details of these tests are not included herein. The safetyproperties were used to determine whether the reactive materials had alow level of sensitivity (green line (“GL”)), an intermediate level ofsensitivity (yellow line (“YL”)), or a high level of sensitivity (redline (“RL”)). The overall rating assigned to each of the reactivematerials is the lowest (most conservative) rating received from thesafety tests.

Safety results for the formulations described in Example 1 are shown inTables 4-6.

TABLE 4 Safety Results for the Intermetallic and Thermite ReactiveMaterials. Mix ABL Friction SBAT Onset TC ESD Unc. TC Impact ABL ImpactRussian DDT No. (lbs @ fps) (° F.) (J) (in.) (cm) (@500 psi) 1791-97-10<25 @ 2 (RL)  368 (GL) <0.05 (RL) >46 80 NT 1791-97-11 <25 @ 2 (RL)  362(GL) <0.05 (RL) >46 80 NT STR: 22235 800 @ 8 (GL) >500 (GL)   4.5(YL) >46 21 (GL) NT STR: 22037 800 @ 8 (GL) >500 (GL)   6.75 (GL)   45(GL) 21 (GL) NT STR: 22080 800 @ 8 (GL) >500 (GL)  >8 >46 80 (GL) NT1836-90C 800 @ 8 (GL) 482 (GL) >8 42.11 (GL) NT No Go 1836-90D 800 @ 8(GL) 481 (GL) >8  41.5 (GL) NT No Go STR: 22610  50 @ 8 (YL) >500(GL)  >8 >46 6.9 (GL)  NT 1791-100-1 130 @ 4 (YL) 425 (GL)  0.65(YL) >46 3.5 (YL)  NT 1791-100-2  25 @ 6 (YL) 441 (GL) <0.05 (YL) >461.8 (RL)  NT 1943-77A 800 @ 8 (GL) >500 <0.05 (RL) >46 NT NT 2002-1-1800 @ 8 (GL) >500 <0.05 (YL) >46 NT NT 1943-77B 660 @ 4 (YL) >500 <0.05(RL)  45 NT NT 1943-77D 800 @ 8 (GL) >500 >8 >46 NT NT 1661-60A 100 @ 4(YL) 357 (GL) >8 >46 NT No Go 1661-60D 100 @ 6 (YL) 338 (GL) >8 >46 NTNo Go 1775-50A 800 @ 8 (GL) 349 (GL) >8 >46 NT No Go 1791-97-1 800 @ 8(GL) >500  0.65 (YL) >46 80 (GL) NT 1791-97-2 800 @ 8 (GL) >500 <0.05(YL) >46 80 (GL) NT 1791-97-3 800 @ 8 (GL) 458 (GL) <0.05 (YL) >46 80(GL) NT 1791-97-4 130 @ 4 (YL) 440 (GL) <0.05 (RL) >46 80 (GL) NT1791-97-5 240 @ 4 (YL) 410 (GL) <0.05 (RL) >46 80 (GL) NT 1791-97-7 240@ 4 (YL) >500 <0.05 (YL) >46 80 (GL) NT 1791-97-8 100 @ 3 (YL) 391 (GL)<0.05 (RL) >46 64 (GL) NT 1791-97-9 130 @ 3 (YL) 425 (GL) <0.05 (YL) >4680 (GL) NT 1791-97-12 180 @ 8 (GL) 447 (GL) <0.05 (RL) >46 80 (GL) NT1943-26D 100 @ 8 (GL) >500 >8 43.29 (GL) 1.8 (RL)  NT 1943-26F 800 @ 8(GL) >500 <0.05 (YL)   44 (GL) 13 (GL) NT 1943-26E 800 @ 8 (GL) >500<0.05 (YL) >46 21 (GL) NT 1943-37A 240 @ 8 (GL) 276 (YL)  6.9 (YL)  446.9 (GL)  NT

TABLE 5 Safety Results for the Class 1.1 Reactive Materials. Mix ABLFriction SBAT Onset TC ESD Unc. TC Impact ABL Impact Russian DDT No.(lbs @ fps) (° F.) (J) (in.) (cm) (@500 psi) PAX-2A 560 @ 8 (GL) 360(GL) >8 41.67 (GL)  64 (GL) Go PAX-22a - 240 @ 8 (GL) 319 (GL) >8 23.50(GL)  13 (GL) Go 1855-70 Form 10 - 100 @ 8 (GL) 326 (GL) >8 NT 6.9 (GL)Go 1855-66 PAX-11c - 130 @ 8 (GL) 330 (GL) >8 NT 6.9 (GL) Go 1943-02PAX-11c - 240 @ 8 (GL) 301 (GL) >8  21.5 (GL)  13 (GL) Go 1943-15 Form9 - 240 @ 8 (GL) 313 (GL) >8 NT 6.9 (GL) Go 1855-53 1943-03H 800 @ 8(GL) 371 (GL) >8 (GL) 18.67 (GL) 1.8 (RL) Go, 9.8″ Run 1943-03I 800 @ 8(GL) 409 (GL) >8 (GL)  13.0 (GL) 3.5 (YL) Go, 5.7″ Run 1943-03F 800 @ 8(GL) 350 (GL) 7.5 (YL)  18.45 (GL) 6.9 (GL) Go, 3.2″ Run 1943-04G  25 @6 (YL) 310 (GL) >8 (GL)  19.9 (GL) 3.5 (YL) NT 1943-03E 800 @ 8 (GL) 287(YL) >8 (GL) 11.14 (GL) 1.1 (RL) Go, 7.2″ Run 1943-03J 800 @ 8 (GL) 336(GL) >8 (GL) 15.55 (GL) 1.8 (RL) Go, 5.4″ Run 1943-04F  25 @ 4 (YL) 336(GL) >8 (GL) 18.64 (GL) 1.8 (RL) NT 1943-04F-B  25 @ 4 (YL) 345 (GL) 7.8(YL)  22.40 (GL) 3.5 (YL) NT 1943-04B  25 @ 3 (RL) 301 (GL) >8 (GL) 10.4 (YL) 1.8 (RL) NT 1943-04A <25 @ 2 (RL)  308 (GL) 7.5 (YL)  13.91(GL) 1.1 (RL) NT 1943-32-17 800 @ 8 (GL) 319 (GL) 1.59 (YL)   5.96 (YL)1.8 (RL) NT

TABLE 6 Safety Results for the INDALLOY ®-containing Reactive Materials.Mix ABL Friction SBAT Onset TC ESD Unc. TC Impact ABL Impact Russian DDTNo. (lbs @ fps) (° F.) (J) (in.) (cm) (@500 psi) 1943-03H 800 @ 8 (GL)371 (GL) >8 (GL) 18.67 (GL) 1.8 (RL) Go, 9.8″ Run 1943-03I 800 @ 8 (GL)409 (GL) >8 (GL)  13.0 (GL) 3.5 (YL) Go, 5.7″ Run 1943-03D 800 @ 8 (GL)287 (YL) >8 (GL) 18.80 (GL) 1.8 (RL) No Go 1943-03B 800 @ 8 (GL) 287(YL) >8 (GL) 21.55 (GL) 6.9 (GL) Go, 5.9″ Run 1943-03F 800 @ 8 (GL) 350(GL) 7.5 (YL)  18.45 (GL) 6.9 (GL) Go, 3.2″ Run 1943-04G  25 @ 6 (YL)310 (GL) >8 (GL)  19.9 (GL) 3.5 (YL) NT 1943-04H  25 @ 2 (RL) 345 (GL)7.25 (YL)  16.82 (GL) <1.1 (RL)  NT 1943-03G 800 @ 8 (GL) 316 (GL) >8(GL)  16.0 (GL) 1.8 (RL) Go, 0.0″ Run 1943-03E 800 @ 8 (GL) 287 (YL) >8(GL) 11.14 (GL) 1.1 (RL) Go, 7.2″ Run 1943-03J 800 @ 8 (GL) 336 (GL) >8(GL) 15.55 (GL) 1.8 (RL) Go, 5.4″ Run 1943-04F  25 @ 4 (YL) 336 (GL) >8(GL) 18.64 (GL) 1.8 (RL) NT 1943-04F-B  25 @ 4 (YL) 345 (GL) 7.8 (YL) 22.40 (GL) 3.5 (YL) NT 1943-03C 800 @ 8 (GL) 287 (YL) >8 (GL) 13.17 (GL)1.8 (RL) Go, 2.8″ Run 1943-03K 800 @ 8 (GL) 292 (YL) 7.30 (YL)  13.17(GL) 3.5 (YL) Go, 5.3″ Run 1943-34A  50 @ 4 (YL) 334 (GL) >8 (GL)  9.25(YL) 1.8 (RL) NT 1943-34B  25 @ 3 (RL) 315 (GL) >8 (GL)  8.0 (YL) 1.8(RL) NT 1943-34C  25 @ 4 (YL) 336 (GL) >8  8.7 (YL) 3.5 (YL) NT 1943-04C 25 @ 4 (YL) 331 (GL) >8 (GL) 16.33 (GL) 3.5 (YL) NT 1943-04C-B  25 @ 4(YL) 376 (GL) >8 (GL) 18.64 (GL) 3.5 (YL) NT 1943-34D 560 @ 8 (GL) 324(GL) >8  39.8 (GL)  11 (GL) NT 1943-04B  25 @ 3 (RL) 301 (GL) >8 (GL) 10.4 (YL) 1.8 (RL) NT 1943-04A <25 @ 2 (RL)  308 (GL) 7.5 (YL)  13.91(GL) 1.1 (RL) NT 1943-04D  50 @ 3 (YL) 317 (GL) >8 (GL) 14.33 (GL) 3.5(YL) NT 1943-04D-B  50 @ 3 (YL) 321 (GL) 1.70 (YL)  13.00 (GL) 1.8 (RL)NT 1943-34E 660 @ 8 (GL) 317 (GL) 7.50 (YL)  30.45 (GL) 6.9 (GL) NT1943-04E  50 @ 4 (YL) 309 (GL) >8 (GL) 43.86 (GL) 3.5 (YL) NT 1943-04E-B 25 @ 4 (YL) 326 (GL) >8 (GL)  8.23 (YL) 1.8 (RL) NT 1943-32-17 800 @ 8(GL) 319 (GL) 1.59 (YL)   5.96 (YL) 1.8 (RL) NT 1943-37B  50 @ 4 (YL)328 (GL) 7.50 (YL)    14 (GL) 1.8 (RL) NT

Formulations having sufficient safety and sensitivity properties wereselected for testing in reactive material bullets. Formulations thatinitiated on the Russian DDT test were not evaluated in reactivematerial bullets due to safety concerns.

Example 3 Reactive Material Bullets Including the Reactive MaterialFormulations

Twenty-four formulations were loaded into a reactive material bullet bypressing the reactive material into the core of the bullet case from thefront. In addition to the formulations shown in Tables 7 and 8,Formulations 1943-32-02, 1943-32-04, 1943-32-05, 1943-32-06, 1943-32-08,1943-32-09, 1943-32-10, 1943-32-17, and 1791-100-1 were also tested. Thetip was then inserted into the case to form the reactive materialbullet. The formulations were tested in a reactive material bulletdesigned to penetrate a thin-skinned target, referred to herein as thebullet for thin-skinned targets, or in a reactive material bullet havingincreased penetration and designed to penetrate a thicker-skinnedtarget, referred to herein as the bullet for thicker-skinned targets.

Energy release and initiation threshold of the reactive materialformulations were determined by firing the reactive material bullets 2from a 50-caliber gun 10 into a series of steel plates having athickness of ⅛-inch at ATK Thiokol's hundred-yard test range, which isschematically shown in FIG. 2. The steel plate array included three,⅛-inch-thick, carbon steel witness plates 12 in series followed by a½-inch-thick, carbon steel backer plate 14. The distance between eachsteel plate was 6 inches. The plates were rigidly held together usingsteel rods and 6-inch spacers and were mounted on a steel stand.

Data collected for each reactive material bullet test includedinitiation thresholds, overpressure, IR intensity, and plate damagemeasurements. High-speed video 16 was used to quantify and document theinitial visible reaction (defined as initiation threshold), location ofthe initial reaction, plume size, relative visible light intensity, andreaction duration. The high-speed video 16 was used to visuallyascertain the blast from each reactive material bullet 2. An infrared(“IR”) spectrometer 18 and IR light screens 20 were used to record themagnitude of light, or flame intensity, emitted by each reactivematerial bullet 2. Plate damage was measured to determine the mechanicalenergy of each reactive material formulation. Pressure output wasmeasured between each steel plate using overpressure gauges 22 andamplifiers 24. This data was acquired using a data acquisition system26.

Data for the best performing formulations is shown in Tables 7 and 8. Inaddition, the weight of each reactive material bullet 2 is shown inthese tables.

TABLE 7 Plate Damage, Plume Size, IR Intensity, and Overpressure of theFormulations Tested in the Bullets for Thin-Skinned Targets. Area ofTransducer Data Reactive Avg. Avg. Max Plate Plume Size Peak Mix BulletMaterial Ullage Comp. Damage Height Width Area Avg. IR Transducer OutputNo. No. Formulation (in.) Wt. (g) (in²) (ft) (ft) (ft²) Integral # (psi)1791-100-2 601 W/KP/VITON ® 0.2280 8.837 2.9 2 1 2 31 4 8 1943-32-13 607IND174/KP/Binder 0.2293 4.419 1.7 0.5 0.5 0.25 0 3 5.5 1943-32-03 622Al/Zr/VITON ® 0.2325 5.169 2.9 3.5 1 3.5 1121 4 2.5 1943-32-07 629Mg/CuO/VITON ® 0.2270 3.008 0.6 1.5 1 1.5 126.7 3 & 4 9 1943-32-12 634Hf/THV220 0.2335 12.989 3.8 6 4 24 795 4 9.5 1943-32-01 640Al/Boron/VITON ® 0.2290 2.864 1.7 0.2 0.2 0.04 0 1-4 1 2002-1-1 655Zr/PTFE 0.227 6.350 1.3 3 2.5 7.5 117 3 4.5 1943-34D 659 IND174 & 40% KP0.233 6.826 1.3 1.5 1 1.5 17.1 3 6.5 1943-34E 661 IND174 & 20% KP 0.2319.522 1.6 2 1 2 51.3 4 10 PAX-2A 665 HMX/Binder 0.228 3.148 3.8 1 1 1 03 & 4 11.5 1943-37A 672 Al/KP/Si/THV 0.23025 4.206 2.2 2.5 1.5 3.75195.2 3 & 4 11.5 1943-37B 674 IND174/Al/Si/S/KP/BG/A/F 0.2325 5.090 2.03 1.5 4.5 159.3 3 & 4 11.5 PAX-2A & 676 HMX/Binder & 0.227 1.743/3.8681.8 2.5 1.5 3.75 77.5 2, 3, & 4 11.5 1943-37A Al/KP/Si/THV Mix no.1943-32-12 (Hf/THV220) is analogous to Mix no. 1943-26E

TABLE 8 Plate Damage, Plume Size, IR Intensity, and Overpressure of theFormulations Tested in the Bullets for Thicker-Skinned Targets. Area ofTransducer Data Reactive Avg. Avg. Max Plate Plume Size Peak Mix BulletMaterial Ullage Comp. Damage Height Width Area Avg. IR Transducer OutputNo. No. Formulation (in.) Wt. (g) (in²) (ft) (ft) (ft²) Integral # (psi)1791-100-2 605 W/KP/VITON ® 0.583 5.9115 1.8 0.5 1 0.5 25.9 3 61943-32-13 610 IND/KP/Binder 0.570 2.9095 0.7 0.4 1 0.4 5.1 4 71943-32-11 616 Zr/THV - 65/35 0.579 3.951 0.25 1 1 1 34.8 4 2.51943-32-03 625 Al/Zr/VITON ® 0.570 3.4855 0.45 3 0.5 1.5 ET 4 21943-32-07 632 Mg/CuO/VITON ® 0.582 2.021 0.45 1.5 1 1.5 102 4 51943-32-12 637 Hf/THV220 0.570 8.7535 2.4 5 4 20 ET 4 8.5 PAX-2AHMX/Binder 0.576 1.967 0.49 1.5 0.5 0.75 52 4 6

Pressure-versus-time profiles for the reactive material bullets thatincluded the formulation Nos. 1791-100-2, 1791-100-2, 1943-32-13,1943-32-12, 1943-32-11, 1943-32-03, 1943-32-03, 1943-32-07, 1943-32-07,1943-32-12, PAX-2A, and PAX-2A are shown in FIGS. 3-14, respectively.Still photos taken from high-speed video for the reactive materialbullets that included the formulation Nos. 1791-100-2 (bullet forthin-skinned targets), 1791-100-2 (bullet for thicker-skinned targets),1943-32-13 (bullet for thin-skinned targets), 1943-32-13 (bullet forthicker-skinned targets), 1943-32-11 (bullet for thicker-skinnedtargets), 1943-32-03 (bullet for thin-skinned targets), 1943-32-03(bullet for thicker-skinned targets), 1943-32-07 (bullet forthin-skinned targets), 1943-32-07 (bullet for thicker-skinned targets),1943-32-12 (bullet for thin-skinned targets), 1943-32-12 (bullet forthicker-skinned targets), 1943-32-01 (bullet for thin-skinned targets),2002-1-1 (bullet for thin-skinned targets), 1943-34D (bullet forthin-skinned targets), 1943-34E (bullet for thin-skinned targets),PAX-2A (bullet for thin-skinned targets), 1943-37A (bullet forthin-skinned targets), 1943-37B (bullet for thin-skinned targets), andPAX-2A & 1943-37A (bullet for thin-skinned targets) are shown in FIGS.15-33, respectively.

The IR intensity-versus-time profiles for the reactive material bulletsthat included the formulation Nos. 1791-100-2, 1791-100-2, 1791-100-2,1943-32-13, 1943-32-11, 1943-32-03, 1943-32-03, 1943-32-07, 1943-32-07,1943-32-07, 1943-32-12, 2002-1-1, 1943-34D, 1943-34E, PAX-2A, PAX-2A,1943-37A, 1943-37A, 1943-37B, and PAX-2A & 1943-37A are shown in FIGS.34-53, respectively.

The reactive materials of the present invention exhibited a high-energyoutput when tested in the reactive material bullets. These reactivematerials provided blast and incendiary effects in the reactive materialbullets. The reactive materials that included the class 1.1 explosivesexhibited enhanced performance. However, the reactive materials that didnot include the class 1.1 explosives, such as the intermetallic-typecompositions, the thermite-type compositions, and theINDALLOY®-containing compositions also exhibited good performance.

The best performing reactive materials were determined based on theformulations having the highest overpressure, earliest initiation(determined by the high-speed video and pressure curves), greatest platedamage, infrared intensity, or largest plume size/intensity (determinedby the high-speed video). Several formulations of the reactive materialwere successful in more than one of these categories. Formulation Nos.1791-100-2, 1943-32-03, 1943-32-12, Pax-2A, 1943-37A, and 1943-37Bshowed the best performance in plate damage in the bullets forthin-skinned targets, as shown in FIG. 54. Fonnulations 1943-32-03,1943-32-12, 2002-1, 1943-37A, 1943-37B, and Pax 2A & 1943-37A showed thebest performance for plume size in the bullets for thin-skinned targets,as shown in FIG. 55. Formulations 1943-32-07, 1943-32-12, 1943-34E,Pax-2A, 1943-37A, 1943-37B, and Pax 2A & 1943-37A showed the bestperformance for pressure output in the bullets for thin-skinned targets,as shown in FIG. 56.

Formulation Nos. 1791-100-2, 1943-32-12, and 1943-32-13 showed the bestperformance in plate damage in the bullets for thicker-skinned targets,as shown in Table 8. Formulations 1943-32-11, 1943-32-03, 1943-32-07,and 1943-32-12 showed the best performance for plume size in the bulletsfor thicker-skinned targets, as shown in Table 8.

Formulations 1791-100-2, 1943-32-13, 1943-32-07, 1943-32-12, and Pax-2Ashowed the best performance for pressure output in the bullets forthicker-skinned targets, as shown in Table 8.

While the invention may be susceptible to various modifications andalternative forms, specific embodiments have been shown by way ofexample in the drawings and have been described in detail herein.However, it should be understood that the invention is not intended tobe limited to the particular forms disclosed. Rather, the invention isto cover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the followingappended claims.

1-5. (canceled)
 6. The reactive material of claim 33, wherein thereactive material consists of tungsten, boron, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 7. The reactive material ofclaim 31, wherein the reactive material consists of aluminum, zirconium,and the copolymer of vinylidenefluoride-hexafluoropropylene.
 8. Thereactive material of claim 31, wherein the reactive material consists ofaluminum, titanium, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 9. The reactive material ofclaim 33, wherein the reactive material consists of aluminum, boron, andthe copolymer of vinylidenefluoride-hexafluoropropylene.
 10. Thereactive material of claim 33, wherein the reactive material consists oftitanium, boron, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 11. The reactive material ofclaim 33, wherein the reactive material consists of zirconium, boron,and the copolymer of vinylidenefluoride-hexafluoropropylene.
 12. Thereactive material of claim 33, wherein the reactive material consists ofhafnium, boron, and the copolymer ofvinylidenefluoride-hexafluoropropylene. 13-30. (canceled)
 31. A reactivematerial consisting of at least two metals selected from the groupconsisting of aluminum, titanium, and zirconium, and a copolymer ofvinylidenefluoride-hexafluoropropylene.
 32. (canceled)
 33. A reactivematerial consisting of at least one metal, boron, and a copolymer ofvinylidenefluoride-hexafluoropropylene.
 34. The reactive material ofclaim 33, wherein the at least one metal consists of at least one ofaluminum, hafnium, magnesium, titanium, tungsten, and zirconium. 35.(canceled)
 36. A reactive material comprising at least one metal, cupricoxide at from approximately 18% by weight to approximately 78% by weightof a total weight of the reactive material, and a copolymer ofvinylidenefluoride-hexafluoropropylene.
 37. The reactive material ofclaim 36, wherein the at least one metal comprises at least one ofaluminum, hafnium, magnesium, titanium, tungsten, and zirconium.
 38. Thereactive material of claim 36, wherein the reactive material consists ofthe at least one metal, the cupric oxide at from approximately 18% byweight to approximately 78% by weight of the total weight of thereactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 39. The reactive material ofclaim 36, wherein the reactive material comprises zirconium, cupricoxide at from approximately 18% by weight to approximately 78% by weightof the total weight of the reactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 40. The reactive material ofclaim 36, wherein the reactive material comprises aluminum, cupric oxideat from approximately 18% by weight to approximately 78% by weight ofthe total weight of the reactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 41. The reactive material ofclaim 36, wherein the reactive material comprises magnesium, cupricoxide at from approximately 18% by weight to approximately 78% by weightof the total weight of the reactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 42. The reactive material ofclaim 36, wherein the reactive material comprises titanium, cupric oxideat from approximately 18% by weight to approximately 78% by weight ofthe total weight of the reactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 43. The reactive material ofclaim 36, wherein the reactive material comprises hafnium, cupric oxideat from approximately 18% by weight to approximately 78% by weight ofthe total weight of the reactive material, and the copolymer ofvinylidenefluoride-hexafluoropropylene.
 44. A projectile comprising thereactive material of claim
 31. 45. A projectile comprising the reactivematerial of claim
 33. 46. A projectile comprising the reactive materialof claim 36.